Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 1 of 13

THE DESIGN OR PART THEREOF CONTAINED IN THIS DOCUMENT WAS DEVELOPED FOR TAKREER AND MAY BE UTILISED BY TAKREER FOR ANY PURPOSE RELATING TO THE CONSTRUCTION, MAINTENANCE OR OPERATION OF THE PROJECT.

ELECTRONIC DOCUMENTS, ONCE PRINTED, ARE NON-CONTROLLED AND MAY BECOME OUTDATED

HAIL WATER SUPPLY SYSTEM

PROJECT

(Vibration Monitoring System)

Vendor Reference : AEE2007-RTCC-HAIL Contractor P.O. : SY-PU-EM-CSP1200-PO-EL-013-09 Vendor Document No. : AEE2007-RTCC-HAIL-FDS-000

CONTRACTOR : AL RASHID TRADING & CONTRACTING CO (RTCC) SUPPLIER : ROCKWELL AUTOMATION

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 2 of 13

Approved Rev Date Reason For Issue Prep

Chkd

Apprd

EM PM PMC COMPANY

00 07.06.09 For Approval AS SG SG

01 16.06.09 For Approval AS SG SG

02 23.08.09 For Approval AS SG SG

NOTES:

1. Revisions are denoted as follows:

(a) By a vertical line in the right-hand margin against the revised text.

(b) By a triangle symbol for graphics, the revision number being denoted within the symbol. Revision symbols are positioned adjacent to the revision.

2. Prep = VENDOR/SUPPLIERs specialist

Chkd = Checked by VENDOR/SUPPLIERs specialist

Apprd = Approval by VENDOR/SUPPLIERs specialist, if required as per job quality plan

EM = CONTRACTORs Engineering Manager

PM = CONTRACTORs Project Manager

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 3 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

PARAGRAPHS REVISED IN THIS ISSUE Para. No. Para. No. Para No. Para. No.

5 Added the Customer Supplied

drawing

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 4 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

TABLE OF CONTENTS 1. INTRODUCTION ............................................................................................................................5 1.1 PURPOSE OF THE DOCUMENT ..................................................................................................5 1.2 REFERENCE DOCUMENTS .........................................................................................................5 2 BILL OF MATERIAL ......................................................................................................................6 2.1 HARDWARE...................................................................................................................................6 3 SYSTEM ARCHITECTURE............................................................................................................7 4 SENSOR MOUNTING DETAILS....................................................................................................9 5 DRAWINGS..................................................................................................................................13

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 5 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

1. INTRODUCTION

1.1 PURPOSE OF THE DOCUMENT The purpose of the Functional Design Specification is to provide a general configuration for the Vibration Monitoring System applied to the Hail Water Project This document defines the functional requirements for the Vibration Monitoring System to be supplied by M/s Rockwell Automation Middle East This FDS incorporates, and expands upon, information contained in the RFQ documents, as issued at the Project tender stage, and will be used to validate the Vibration Monitoring System functionality This document will be supported by further specifications and design documents forming the contents of the total system documentation. The purpose of this document is not intended to address how functions will be designed and implemented but to address what functions are available.

1.2 REFERENCE DOCUMENTS This document is best understood with the listed documents available, and they will be referenced to in this document text when relevant.

Rockwell Auutomation offer ref QS09/12 rev 3.0 dated April 12, 2009

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 6 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

2 BILL OF MATERIAL 2.1 HARDWARE

CAT NO. Description Bazakha Pumps

Tawaren Pumps

Total Qty

Power Supply System

1606-XL60DR SWITCH MODE POWER SUPPLY, N+1 REDUNDANCY, INPUT: SINGLE PHASE 100..120, 200..240V AC MANUAL SELECT, 160-375V DC, OUTEST PLUGOUT: 24V DC 2.5A,

8 8 16

Vibration sensors & Studs

EK-46804I EK-46804I: SPLASH PROOF CABLE ASSEMBLY, 32FT; 3-SOCKET CONNECTOR TO BLUNT CUT; SHIELDED 3-CONDUCTOR; TEFLON JACKET

16 16 32

EK-48956 9842V2 4VELOCITY PROCESS SENSOR 16 16 32

EK-44153+EK-44156 STUD 1/4 -28 TO 1/4 - 28 WITH BASE FOR SCREW MOUNTING 16 16 32

Proximity Sensor & Accesories

871TM-DH5NE18-H2

INDUCTIVE PROXIMITY SENSORS, ST ST FACE/THREADED ST ST BARREL, SHORT BODY, DC, 2-WIRE, 18 MM DIA, SHIELDED, LENGTH 55.4 MM, SENSING RANGE 5 MM, NO, TOUGHLINK CABLE 2 M,

8 8 16

871A-BRS18 MOUNTING BRACKET FOR 'INDUCTIVE PROXIMITY SENSORS 8 8 16

871A-KT18 TEFLON END CAPS FOR INDUCTIVE PROXIMITY SWITCH, SHIELDED, DIA. 18 MM SHIELDED, 8 8 16

871T-N4 INDUCTIVE PROXIMITY SENSORS, ACCESSORY, MOUNTING NUTS FOR CYLINDRICAL SENSOR, PLASTIC, DIA. 13 MM, NICKEL PLATED BRASS,

8 8 16

871A-LWN18 INDUCTIVE PROXIMITY SENSORS, ACCESSORY, LOCK WASHERS, DIA. 18 MM, PLATED METAL, 8 8 16

XM 220 Speed Protection Modules

1440-SPD02-01RB XM-220 DUAL CHANNEL SPEED MONITOR, 4 4 8

1440-TB-B XM POSITION MODULE TERMINAL BASE, 4 4 8

NEMA 4 X Enclosure with Glass Window

1440-E6P600N4XW XM ENCLOSURE 6 POSITION NEMA4x RATED ENCLOSURE with window 4 4 8

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 7 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

3 SYSTEM ARCHITECTURE Refer System Architecture drawing Below

The main intention of the Vibration Monitoring System is to monitor the Hail Water Project Pumping Station Pumps Vibration Levels and Speed. The Vibration System deployed in this project consists of : a. Model 9842V Velocity Sensors with 4-20 mA output for Vibration Monitoring b. Model 871A Non-Contact Pick-ups for Speed Measurement c. XM-220 Speed Measurement module d. Power Supplies with Redundancy e. Enclosure

VIBRATION SENSORS

Junction Box

Proximity SENSORS

PLC

= XM-220

Scope of supply

= Power Supply

Vibration & Reverse rotation protection system for HAEL Villages

4-20mA signals

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 8 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Two 24 V DC Power Supplies, for input supply of 220/110V AC with Redundancy are mounted along with XM-220 Speed Measurement Module in the enclosure. The enclosure to be located at the site within a distance of 10 Meters of the Pumps. The 24 V DC redundant supply is also powers the XM-220 Module. The Vibration Sensors Mounted on the Motor/Pump bearing housing as recommended by the client are connected to 24V DC redundant power supply from the System Enclosure. The 4-20 mA output from each Sensor is directly connected to the PLC as shown in Drawing Ref. # AEE2009-RTCC-HAIl-06 for Alarm and Trip purposes. For Speed measurement System two (2) Non-Contact pick-ups for each pump are mounted. The first one is meant for the Speed Measurement and the Second one mounted at 90 Deg.to the first one is used for Reverse Rotation sensing. XM-220 Speed measurement module supplies 24DC Power Supply to both the Sensors. For Sensing the speed, the gap between the Key Phaser/Key Hole and the Sensor face to be adjusted to 5 mm approximately. From XM-220 module, a 4-20 mA Signal is available for the speed measurement and one Change Over Relay Contacts available for the Reverse Rotation Speed Monitoring.

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 9 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

4 SENSOR MOUNTING DETAILS Vibration Sensor Mounting The sensor mounting is the most important consideration in getting accurate readings from the sensor. Mounting sensors directly on the case The actual frequency range of a sensor depends on how well it is attached to the machine. Mounting sensors directly to the machine is the most common mounting technique for many vibration sensors. Sensors designed for stud mounting have a base that is drilled and tapped for that purpose. There are two common methods of stud mounting a sensor. In both cases, it is crucial to prepare a flat, smooth, and clean area at least as large as the base of the sensor. If the surface is not prepared properly, some of the vibration energy will be lost, and will not be transmitted to the sensor. Improper mounting can also allow chatter, creating false data. Note: Rocwell recommends following the API 670 requirements for surface finish and flatness, even for non-API installations. If the surface is not properly prepared, it can reduce the detection of higher frequencies.

1. The first method is to spot face the surface, then drill and tap a hole in the machine case or bearing housing where you want to install the sensor. Per the requirements of API 670 appendix C.2.1, the surface finish should be within 0.8 micrometers (.032 mil, or 32 inches) and the flatness should be below 25 micrometers (1 mil).

2. Clean the finished area to remove any rust, dirt, paint, or grease. 3. Insert a set screw leaving enough of the screw above the case to attach the sensor, 4. Typically 1/4 inch. Some sensors come with captive mounting screw and do not need a

separate set screw. 5. Apply a thin coating of grease or silicone lubricant to the surface. 6. Use a torque wrench to attach the sensor. Refer to the following table. 7.

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 10 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

XM-220 Dual Speed Module for Reverse Rotation Monitoring: The XM-220 Dual Speed module is a member of the Allen-Bradley XM series, a family of DIN rail mounted condition monitoring and protection modules that operate both in stand-alone applications or integrate with programmable Logic Controllers (PLCs) and control system networks. The XM-220 is a two channel module that accepts input from any two tachometers of any standard type including eddy current probes, magnetic pickups, optical tachometers, and TTL output devices. It measures speed, rotor acceleration, and peak speed and is capable of detecting zero speed, locked rotor, and reverse rotation conditions. It is also used as a component of the XM Electronic Over speed Detection system. The XM-220 will be configured (using the configuration software) to operate in reverse rotation mode. Reverse Rotation Mode - The two sensors are used to monitor speed and direction of a single shaft. The two sensors must be mounted out of phase from each other so that the rotational direction can be determined by monitoring which sensor the shaft keyway passes first. Position the sensors so that:

The keyway passes Channel 1 sensor before it passes Channel 2 sensor as the machine rotates in the forward direction.

The sensors are more than 10 degrees apart and less than 170 degrees apart in the direction of forward

rotation; 90 degrees is optimum

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 11 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 12 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

Inductive Proximity Sensor and its accessories dimensions details

Functional Design Specification

RTCC HAIL WATER SUPPLY SYSTEM

Rev. 2 Date: 23.08.09 PROJECT NO CSP#1200 Doc. No.: AEE2009-RTCC-HAIL-FDS-000

Page 13 of 13

AEEE2009-RTCC-HAIL-FDS-000 Rev 02

5 DRAWINGS See attached drawing AEE2009-RTCC-HAIL-01 Total 7 pages Sheet 01 Sensor Mounting Arrangement Overview Sheet 02 Vibration Sensor Mounting Arrangement Sheet 03 Speed Sensor Mounting Arrangement Sheet 04 NEMA4 X Enclosure General Arrangement with Enclosure BOQ Sheet 05 AC Power Distribution Sheet 06 DC Power Distribution Sheet 07 - System Wiring Diagram See attached drawing 091013548-GA updated for location of Sensors